Accessory mounting system and helmet including same

ABSTRACT

An accessory mounting system (30) and a helmet (10) that includes such systems are disclosed. The accessory mounting system (30) includes a plate (32) adapted to be permanently connected to a substantially continuous portion of a ballistic layer (12) of a helmet, where the ballistic layer has an outer surface (14). The plate (32) includes an inner surface (34) and an outer surface (36), where the inner surface of the plate is adapted to be disposed in contact with an outer surface of the ballistic layer. The accessory mounting system also includes an accessory rail (50) adapted to be removably connected to the plate, where the accessory rail includes an inner surface (52) and an outer surface (54). The inner surface of the accessory rail is adapted to be disposed in contact with the plate.

BACKGROUND

Head gear such as helmets utilized, e.g., in military and police applications, have been developed that support one or more accessories such as flashlights or cameras. These accessories can assist the wearer in performing various tasks. For example, flashlights can be utilized to allow the wearer to more easily see the immediate surroundings. Frequently, the position of the flashlight or other accessory may need to be adjusted, or the accessory may need to be removed and replaced with another accessory. Further, two or more accessories may need to be utilized concurrently. When no accessories are required, the weight of the head gear can be reduced by removing such accessories.

To more easily attach and remove accessories from a helmet or head gear, various mounting systems have been developed that can be connected to the helmet. Such systems often include a rail or groove within which a mount attached to an accessory can be disposed. The rail can allow a wearer to adjust the accessory relative to the helmet. A rail is typically mounted onto the helmet by drilling one or more holes through the helmet and inserting a bolt through the rail and helmet that is fastened to the helmet with a nut disposed within an interior space of the helmet. Although this method of attaching the rail to the helmet can be robust, the one or more holes drilled through the helmet can weaken the helmet. Further, one or both of the bolt and nut can become a secondary projectile that could impact the wearer's head when the helmet encounters a ballistic event.

To address these concerns, some helmets include one or more bosses of non-ballistic material that can be molded into an external surface of the helmet. An accessory rail can be attached to the bosses with self-tapping screws that are directed into the bosses. This design does not, however, allow repeated removal and reattachment of the rail from the helmet as threads formed in the bosses by the screws (or preformed) tend to become stripped. Once the threads are stripped, the bosses will no longer hold the rail in place, and the entire helmet has to be discarded.

SUMMARY

In general, the present disclosure provides various embodiments of an accessory mounting system and a helmet that includes such system. The accessory mounting system can include a plate and an accessory rail that is adapted to be removably connected to the plate. The plate can be connected to the helmet without the need to dispose holes through the helmet or to form molded bosses in the helmet. In one or more embodiments, the plate is adapted to be permanently connected to a substantially continuous portion of a ballistic layer of a helmet.

In one aspect, the present disclosure provides an accessory mounting system that includes a plate adapted to be permanently connected to a substantially continuous portion of a ballistic layer of a helmet, where the ballistic layer includes an outer surface. The plate includes an inner surface and an outer surface, where the inner surface of the plate is adapted to be disposed in contact with an outer surface of the ballistic layer. The accessory mounting system also includes an accessory rail adapted to be removably connected to the plate, where the accessory rail includes an inner surface and an outer surface. The inner surface of the accessory rail is adapted to be disposed in contact with the plate.

In another aspect, the present disclosure provides a helmet that includes a ballistic layer having an inner surface and an outer surface, and an accessory mounting system that includes a plate and an accessory rail removably connected to the plate. The plate includes an inner surface and an outer surface, where the inner surface of the plate is permanently connected to a substantially continuous portion of the ballistic layer by an attachment element. The accessory rail includes an inner surface and an outer surface. Further, the inner surface of the accessory rail is in contact with the plate when the accessory rail is connected to the plate.

In another aspect, the present disclosure provides a method that includes connecting a plate to an outer surface of a ballistic layer of a helmet, connecting an accessory rail to the plate, and connecting an accessory to the accessory rail. The method further includes removing the accessory from the accessory rail, and removing the accessory rail from the plate by moving the accessory rail in a direction orthogonal to an outer surface of a ballistic layer of the helmet.

In another aspect, the present disclosure provides a method that includes disposing a template on an outer surface of a ballistic layer of a helmet, where the template includes an opening that exposes a portion of the ballistic layer; disposing an adhesive on the exposed portion of the ballistic layer through the opening of the template; and connecting a plate to the exposed portion of the ballistic layer utilizing the adhesive. The method further includes applying pressure to the plate, and curing the adhesive such that the plate is permanently attached to the ballistic layer of the helmet.

In another aspect, the present disclosure provides an accessory mounting system kit that includes a template adapted to be disposed on an outer surface of a ballistic layer of a helmet, where the template includes an opening that is adapted to expose a substantially continuous portion of the ballistic layer of the helmet. The kit further includes an adhesive, a surface cleaning component adapted to clean the substantially continuous portion of the ballistic layer of the helmet, and an abrasive element adapted to abrade the substantially continuous portion of the ballistic layer of the helmet. The kit further includes a plate adapted to be permanently connected to the substantially continuous portion of the ballistic layer of the helmet, an accessory rail adapted to be removably connected to the plate, and a fixturing plate adapted to be connected to the helmet and apply pressure to the plate as the plate is connected to the substantially continuous portion of the ballistic layer of the helmet.

All headings provided herein are for the convenience of the reader and should not be used to limit the meaning of any text that follows the heading, unless so specified.

The terms “comprises” and variations thereof do not have a limiting meaning where these terms appear in the description and claims. Such terms will be understood to imply the inclusion of a stated step or element or group of steps or elements but not the exclusion of any other step or element or group of steps or elements. The term “consisting of” means “including,” and is limited to whatever follows the phrase “consisting of” Thus, the phrase “consisting of” indicates that the listed elements are required or mandatory and that no other elements may be present. The term “consisting essentially of” means including any elements listed after the phrase, and is limited to other elements that do not interfere with or contribute to the activity or action specified in the disclosure for the listed elements. Thus, the phrase “consisting essentially of” indicates that the listed elements are required or mandatory, but that other elements are optional and may or may not be present depending upon whether or not they materially affect the activity or action of the listed elements.

The words “preferred” and “preferably” refer to embodiments of the disclosure that may afford certain benefits, under certain circumstances; however, other embodiments may also be preferred, under the same or other circumstances. Furthermore, the recitation of one or more preferred embodiments does not imply that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the disclosure.

In this application, terms such as “a,” “an,” and “the” are not intended to refer to only a singular entity, but include the general class of which a specific example may be used for illustration. The terms “a,” “an,” and “the” are used interchangeably with the term “at least one.” The phrases “at least one of” and “comprises at least one of” followed by a list refers to any one of the items in the list and any combination of two or more items in the list.

The phrases “at least one of” and “comprises at least one of” followed by a list refers to any one of the items in the list and any combination of two or more items in the list.

As used herein, the term “or” is generally employed in its usual sense including “and/or” unless the content clearly dictates otherwise.

The term “and/or” means one or all of the listed elements or a combination of any two or more of the listed elements.

As used herein in connection with a measured quantity, the term “about” refers to that variation in the measured quantity as would be expected by the skilled artisan making the measurement and exercising a level of care commensurate with the objective of the measurement and the precision of the measuring equipment used. Herein, “up to” a number (e.g., up to 50) includes the number (e.g., 50).

Also herein, the recitations of numerical ranges by endpoints include all numbers subsumed within that range as well as the endpoints (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, 5, etc.).

These and other aspects of the present disclosure will be apparent from the detailed description below. In no event, however, should the above summaries be construed as limitations on the claimed subject matter, which subject matter is defined solely by the attached claims, as may be amended during prosecution.

BRIEF DESCRIPTION OF THE DRAWINGS

Throughout the specification, reference is made to the appended drawings, where like reference numerals designate like elements, and wherein:

FIG. 1 is a schematic front view of a helmet that includes an accessory mounting system and a second accessory mounting system.

FIG. 2 is a schematic partial exploded view of the helmet and the accessory mounting system of FIG. 1.

FIG. 3 is a schematic top view of the helmet and accessory mounting systems of FIG. 1.

FIG. 4 is a schematic front perspective view of a plate of the accessory mounting system of FIG. 1.

FIG. 5 is a schematic rear perspective view of the plate of FIG. 4.

FIG. 6 is a schematic front view of an accessory rail of the accessory mounting system of FIG. 1.

FIG. 7 is a schematic rear view of the accessory rail of FIG. 6.

FIG. 8 is a schematic perspective view of an accessory connected to an accessory mount that can be connected to at least one of the accessory mounting system and second accessory mounting system of FIG. 1.

FIG. 9 is a flow chart of one embodiment of a method of connecting an accessory mounting system to a helmet.

FIG. 10 is a schematic plan view of an accessory mounting system kit that includes the plate and accessory rail of the accessory mounting system of FIG. 1.

FIG. 11 is a flow chart of one embodiment of a method of connecting the plate of the accessory mounting system of FIG. 1 to the helmet of FIG. 1.

DETAILED DESCRIPTION

In general, the present disclosure provides various embodiments of an accessory mounting system and a helmet that includes such system. The accessory mounting system can include a plate and an accessory rail that is adapted to be removably connected to the plate. The plate can be connected to the helmet without the need to form holes through the helmet or molded bosses. In one or more embodiments, the plate is adapted to be permanently connected to a substantially continuous portion of a ballistic layer of a helmet.

Various embodiments of accessory mounting systems described herein may provide one or more advantages. For example, one or more embodiments of accessory mounting systems can be connected to a helmet without the need for disposing or forming through-holes in the helmet and bolting a rail of the system to the helmet using the through-holes. This lack of through-holes and bolts can help to maintain the ballistic integrity of the helmet and eliminate bolts and nuts from becoming potential secondary ballistic elements as such bolts and nuts from the connection of the accessory mounting system to the helmet are no longer disposed within an interior space of the helmet. Further, the accessory rail of the system can be mounted to the plate such that the rail can be removed and reattached or replaced without stripping any threaded bosses formed in a ballistic layer of the helmet.

The various accessory mounting systems described herein can be utilized to connect an accessory to a helmet utilizing any suitable connection interface. For example, in one or more embodiments, the accessory mounting system can include a Picatinny rail or tactical rail that is adapted to receive a Picatinny mount connected to an accessory. In general, a Picatinny rail, also known as a MIL-STD-1913 rail, Standardization Agreement 2324 rail, or tactical rail, is a bracket that includes a series of ridges with a T-shaped cross-section interspersed with flat spacing slots. Accessories can be mounted onto the rail, e.g., by sliding them on from one end or the other; by means of a Weaver mount that is clamped to the rail; or by connecting the accessory to the slots between the raised sections. Each slot can have a width of 0.206 in (5.23 mm). Further, the slots can have a center-to-center spacing of 0.394 in (10.01 mm), and a slot depth of 0.118 in (3.00 mm). See MIL-STD-1913 (1995), “Dimensioning of Accessory Mounting Rail for Small Arms Weapons.” Further, one or more embodiments of accessory mounting systems described herein can allow connection of standard devices and accessories that are disposed on Picatinny mounts to be attached to an accessory rail on a combat helmet or other type of head gear. Any suitable accessories can be connected to a rail utilizing one or more embodiments of accessory mounting systems described herein, e.g., flashlights, cameras, gun sights, night vision goggles, protective face shields, etc.

FIGS. 1-3 are various view of one embodiment of a helmet 10. The helmet 10 includes a ballistic layer 12 and an accessory mounting system 30 disposed on an outer surface 14 of the ballistic layer. In one or more embodiments, the helmet 10 can include a second accessory mounting system 31 also disposed on the outer surface 14 of the ballistic layer 12. The description of the various elements and characteristics of the accessory mounting system 30 described herein apply equally to the second accessory mounting system 31. Although illustrated as including two accessory mounting systems 30, 31, the helmet 10 can include any suitable number of accessory mounting systems disposed in any suitable location or locations on the outer surface 14 of the ballistic layer, e.g., one, two, three, four, or more accessory mounting systems. Further, the accessory mounting system 30 can be the same as or different from the second accessory mounting system 31.

The accessory mounting system 30 can be disposed in any suitable location on the outer surface 14 of the ballistic layer 12. In the embodiment illustrated in FIGS. 1-3, the accessory mounting system 30 is disposed on a left side portion 18 of the ballistic layer 12 as viewed by a wearer of the helmet 10. Similarly, the second accessory mounting system 31 can be disposed in any suitable location on the ballistic layer 12. As shown, the second accessory mounting system 31 is disposed on a right side portion 20 of the ballistic layer 12. In one or more embodiments, one or both of the accessory mounting systems 30, 31 can be disposed on a front portion 22, top portion 24, or rear portion 26 (FIG. 3) of the ballistic layer 12.

The helmet 10 can include any suitable helmet having any suitable material or combination materials. Further, the helmet 10 can also include any suitable number of layers. In one or more embodiments, the helmet 10 can include a helmet shell and the ballistic layer 12 disposed on the shell. The ballistic layer 12 can include any suitable material or combination of materials, e.g., thermoplastics, Kevlar, carbon fibers, etc. The ballistic layer 12 can have any suitable thickness or combination of thicknesses. Further, the ballistic layer 12 can have a continuous thickness. In one or more embodiments, the ballistic layer 12 can have a thickness that varies in one or more portions of the helmet 10. The ballistic layer 12 can be the outermost layer of the helmet 10 such that the outer surface 14 of the ballistic layer 12 is the outermost layer of the helmet. In one or more embodiments, the helmet 12 can include an additional layer that is disposed over the ballistic layer 12 such that the outermost surface of the helmet is provided by the additional layer.

In one or more embodiments, at least one of the helmet 10 and the ballistic layer 12 can include a composite. While composites are typically understood to include two or more materials, as understood herein regarding helmet 10 and ballistic layer 12, composites include multiple layers of one or more materials stacked and consolidated together through the use of heat, pressure, adhesives, matrix materials or combinations thereof. In one or more embodiments, the composites include woven or non-woven fabrics or films. When employed herein, the fabrics are formed of fibers or yarns including materials, such as, but not limited to, ultra-high molecular weight polyethylene (UHMWPE) such as DYNEEMA available from DSM or SPECTRA available from Honeywell; para-aramid material such as KEVLAR available from DuPont or TWARON available from Teijin-Aramid; polyamide; polyester; or combinations thereof. From 1 to 100 layers of fabric or film may be included within a stack (for a helmet, from 8 to 100 is more common), including all values and ranges therein.

In one or more embodiments, the fibers for forming at least one of the helmet 10 and ballistic layer 12 can include relatively low density fibers exhibiting a density of less than 1.20 grams per cubic centimeter (such as UHMWPE) as well as relatively high density fibers exhibiting a density of up to 1.60 grams per cubic centimeter (such as Kevlar), including all values and ranges from 0.80 grams per cubic centimeter to 1.60 grams per cubic centimeter. The fibers may also exhibit an elongation at break in the range of greater than 2.5% and up to 5%, including all values and ranges therein, such as 3% to 5%, etc. In addition, the fibers may exhibit a tenacity, which is understood as the force per unit of linear density of an unstrained specimen, of greater than 25 gpd, such as from 25 gpd to 50 gpd, including all values and ranges therein, such as 25 gpd to 45 gpd. The elastic modulus of the fibers may be in the range of 600 gpd to 2500 gpd, including all values and ranges therein. The fibers may exhibit a combination of any two or more of the above characteristics as well.

In the context of the helmet 10, fibers exhibiting one or more of the above properties may form 50% by weight or more of the total weight of the helmet shell, including all values and ranges from 50% by weight to 100% by weight, including all values and ranges therein, including 75% by weight to 95% by weight, 80% by weight to 100% by weight, 90% by weight to 100% by weight, etc. The properties described above, and further below, may be determined by ASTM testing protocols including, for example ASTM-D638-10, ASTM D3822-07, ASTM D3217-07, ASTM C1557-03 and combinations thereof.

In one or more embodiments, the helmet 10 is understood to be a ballistic helmet shell and exhibits a V50 of 300 meters per second or greater at 0°, including all values and ranges from, for example 300 to 1100 meters per second. The V50 is understood as the velocity at which 50% of shots fired may pass through or penetrate a substrate of given grain fragment size (in the present case a 17 grain FSP steel fragment), such as described in MIL STD-662F V50 (1997) and tested according thereto. Embodiments of helmets and helmet shells may include the enhanced combat helmet available from Ceradyne, Inc., Costa Mesa, Calif.

Although not shown, the helmet 10 can include a suspension system disposed within an interior space 11 of the helmet. Any suitable suspension system can be utilized. In one or more embodiments, the suspension system can include a chinstrap that is adapted to keep the helmet on a head of the wearer. Further, the suspension system can be connected to an inner surface 16 of the helmet utilizing any suitable technique or combination of techniques.

The helmet 10 can include any suitable accessory mounting system or systems. As shown in FIG. 2, the accessory mounting system 30 can include a plate 32 and an accessory rail 50 that is adapted to be removably connected to the plate. In one or more embodiments, the plate 32 can be adapted to be permanently connected to a substantially continuous portion of the ballistic layer 12 of the helmet 10. As used herein, the term “substantially continuous portion” means a portion or portions of the ballistic layer 12 of the helmet 10 that does not include any interruptions or any through-holes. For example, the rail 32 of the accessory mounting system 30 is connected to the left side portion 18 of the ballistic layer 12, where the left side portion of the ballistic layer does not include any interruptions or through-holes. In other words, the rail 32 is mounted to the ballistic layer 12 without penetrating through the ballistic layer and into an interior space 11 of the helmet. The substantially continuous portion of the ballistic layer 12 can be disposed in any suitable location or locations on or within the helmet. In one or more embodiments, the substantially continuous portion of the ballistic layer 12 includes one or more of a side portion (e.g., left side portion 18 or right side portion 20), the front portion 22, the top portion 24, and the rear portion 26 of the ballistic layer.

The plate 32 of the accessory mounting system 30 can take any suitable shape or combination of shapes and have any suitable dimensions. For example, as shown in FIG. 2, the plate 32 takes a substantially rectangular shape in a plane orthogonal to a normal to the portion of the ballistic layer that is connected to the plate.

Further, the plate 32 can include any suitable material or combination of materials, e.g., metallic, polymeric, ceramic materials. In one or more embodiments, the plate 32 is rigid. As used herein, the term “rigid” means that the plate has an elastic modulus (Young's Modulus) of at least 0.1 GPa and no greater than 1000 GPa as measured using ASTM E111-04(2010). The plate 32 can be manufactured using any suitable technique or combination of techniques, e.g., injection molding, additive manufacturing (e.g., 3D printing such as fusion deposition modeling and stereo lithography), and subtractive manufacturing (e.g., machining).

FIGS. 4-5 are various perspective views of the plate 32 of the accessory mounting system 30. The plate 32 includes an inner surface 34 and an outer surface 36. The inner surface 34 of the plate 32 is adapted to be disposed in contact with the helmet 10 as shown in FIG. 2. As mentioned herein, the plate 32 can take any suitable shape or combination of shapes. For example, as shown in FIG. 4, the outer surface 36 of the plate 32 can take a substantially planar shape in a plane orthogonal to the outer surface of the helmet. Further, as shown in FIG. 5, the inner surface 34 of the plate 32 can take a curved shape in the plane orthogonal to the outer surface 36. The shape of the inner surface 34 can take a shape that is adapted to conform to a shape of at least a portion of the outer surface 14 of the ballistic layer 12. In one or more embodiments, the plate 32 is adapted to be connected to the left side portion 18 or the right side portion 20 of the helmet 10. In one or more embodiments, the plate 32 is adapted to be connected to the front portion 22 of the helmet 10. In one or more embodiments, the plate 32 is adapted to be connected to the top portion 24 of the helmet 10. Further, in one or more embodiments, the plate 32 is adapted to be connected to the rear portion 26 of the helmet.

Plate 32 also includes a first boss 38 and a second boss 40. The first and second bosses 38, 40 are adapted to receive bolts or other attachment mechanisms that are utilized to attach the accessory rail 50 to the plate 32 as is further described herein. Although depicted as including two bosses 38, 40, the plate 32 can include any suitable number of bosses. The bosses 38, 40 can take any suitable shape and have any suitable dimensions. In one or more embodiments, at least one of the bosses 38, 40 disposed in the plate 32 has a depth that is less than a thickness of the plate such that the boss does not extend to the inner surface 34 of the plate. Further, one or both of the bosses 30, 40 can include threads on an inner surface of the boss that are compatible with a bolt or other attachment mechanism that is utilized to attach the rail 50 to the plate 32.

In one or more embodiments, the plate 32 can include a slot or groove on the outer surface 36 that is adapted to receive a tab disposed on the inner surface 52 of the rail 50 such that the rail can be slidably engaged with the plate.

As mentioned herein, the plate 32 is adapted to be permanently connected to a substantially continuous portion of the ballistic layer 12 of the helmet 10. In one or more embodiments, the plate 32 is adapted to be permanently connected to the substantially continuous portion of the ballistic layer 12 of the helmet 10 utilizing an attachment element that does not penetrate through a thickness of the helmet. Any suitable technique or combination of techniques can be utilized to connect the plate 32 to the substantially continuous portion of the ballistic layer 12 of the helmet 10. In one or more embodiments, the attachment element can include a permanent adhesive. Any suitable adhesive or combination of adhesives can be utilized, e.g., pressure-sensitive adhesives (acrylates, silicones, methacrylates), tapes, structured adhesives (epoxies), etc. In one or more embodiments, the attachment element can include one or more threaded screws or barbs each having a length that is less than a thickness of the ballistic layer 12 of the helmet 10. The threaded screws can be inserted into through-holes formed in the plate 32 such that plate can be permanently connected to the helmet 10.

The accessory mounting system 30 further includes the accessory rail 50. The accessory rail 50 can include any suitable accessory rail. The accessory rail 50 is adapted to be removably connected to the plate 32. As used herein, the term “removably connected” means that the accessory rail can be connected to and disconnected from the plate 32 at least one or more times without damaging the integrity of either the plate or the accessory rail.

The accessory rail 50 can take any suitable shape or combination of shapes and have any suitable dimensions. For example, FIGS. 6-7 are various views of the accessory rail 50 of accessory mounting system 30 of FIG. 1. The accessory rail 50 includes an inner surface 52 and an outer surface 54. The inner surface 52 of the rail 50 is adapted to be disposed in contact with the plate 32. For example, the accessory rail 50 includes a recess 56 disposed in the inner surface 52 that is adapted to receive the plate 32 such that the plate fits within the recess 56 and the accessory rail 50 is in contact with the outer surface 14 of the ballistic layer 12 as shown in FIG. 3.

The inner surface 52 of the rail 50 can take any suitable shape or combination of shapes. In one or more embodiments, the inner surface 52 of the rail 50 can take a curved shape in a plane orthogonal to the outer surface 14 of the ballistic layer 12. In one or more embodiments, the inner surface 52 of the rail 50 can take a shape such that it conforms to one or more portions of the outer surface 14 of the ballistic layer 12. In one or more embodiments, the inner surface 52 can take a shape that conforms to one or more of the side surface (left or right 18, 20), front surface 22, top surface 24, and rear surface 26 of the helmet 10.

The outer surface 54 of the accessory rail 50 can also take any suitable shape or combination of shapes in the plane orthogonal to the outer surface 14 of the ballistic layer 12. In the embodiment illustrated in FIG. 6, a groove 62 disposed in the outer surface 54 of the rail 50 takes a linear shape while end portions of the outer surface take curved shapes in the plane orthogonal to the outer surface.

The accessory rail 50 can be connected to the plate 32 using any suitable technique or combination of techniques. In one or more embodiments, the accessory rail 50 can be adapted to be friction fit onto the plate 32 such that the two elements are snap-fit together. The accessory rail 50 further includes a first through-hole 58 and a through-hole 60. Each through-hole 58, 60 is disposed between the inner surface 52 and the outer surface 54 of the rail 50. Although depicted as including two through-holes 58, 60, the accessory rail 50 can include any suitable number of through-holes. In one or more embodiments, the through-holes 58, 60 are aligned with the bosses 38, 40 of the plate 32 when the rail is connected to the plate. The through-holes 58, 60 can take any suitable shape or combination of shapes and have any suitable dimensions. Further, the through-holes 58, 60 are adapted to receive screws or bolts that are disposed through the through-holes and received by the bosses 38, 40 of the plate 32 such that the rail is removably connected to the plate.

As mentioned herein, the accessory rail 50 can be any suitable accessory rail. As shown in FIG. 6, the accessory rail 50 includes the groove 62 that is adapted to receive an accessory mount the can be utilized to connect an accessory to the accessory rail as is further described in co-owned U.S. Provisional Patent Application Ser. No. 62/239,497, entitled ACCESSORY MOUNTING DEVICE AND SYSTEM USING SAME.

For example, FIG. 8 is a schematic perspective view of one embodiment of an accessory 70 that is connected to an accessory mount 72. The accessory mount 72 can be adapted to engage the groove 62 of the accessory rail 50 and removably connect the accessory 72 to the accessory rail. The accessory 70 can include any suitable accessory or combination of accessories, e.g., flashlights, cameras, gun sights, nightvision goggles, protective face shields, etc. In one or more embodiments, the accessory 70 is releasably connected to the accessory mount 72 such that the mount can be utilized with different accessories. Further, in one or more embodiments, the accessory mount 72 is adapted to allow for adjustment of a position of the accessory 70 on the accessory rail 50 along the groove 62 of the rail.

The user can attach the accessory 70 to the mount 72 using any suitable technique or combination of techniques once the mount is disposed in the desired position relative to the rail 50. In one or more embodiments, a user can first attach the accessory 70 to the mount 72 before connecting the mount to the accessory rail 50. The user can then slide the mount 72 having the accessory 70 mounted thereon into the groove 62 of the rail 50 and position the accessory in any desired location along the groove.

As mentioned herein, the accessory rail 50 can include any suitable material or combination of materials, e.g., metallic, polymeric, ceramic materials. In one or more embodiments, the accessory rail 50 is rigid, e.g., the accessory rail has an elastic modulus (Young's Modulus) of at least 0.1 GPa and no greater than 1000 GPa as measured using ASTM E111-04(2010). The accessory rail 50 can be manufactured using any suitable technique or combination of techniques, e.g., injection molding, additive manufacturing (e.g., 3D printing such as fusion deposition modeling and stereo lithography), and subtractive manufacturing (e.g., machining).

The accessory rail 50 can be connected and disconnected from the plate 32 using any suitable technique or techniques. For example, FIG. 9 is a flow chart of one method 200 that can be utilized to connect and disconnect the accessory rail 50 from the helmet 10. Although described regarding the helmet 10 of FIG. 1, the method 200 can be utilized with any suitable helmet and accessory mounting system. At 202, the plate 32 is connected to the outer surface 14 of the ballistic layer 12 of the helmet 10 using any suitable technique or techniques. For example, in one or more embodiments, the plate 32 can be adhered to the outer surface 14 using any suitable adhesive.

The accessory rail 50 can be connected to the plate 32 using any suitable technique or techniques at 204. In one or more embodiments, the rail 50 can be connected to the plate 32 using one or more threaded screws or bolts that are inserted into through-holes 58, 60 and bosses 38, 40. The accessory 70 can be connected to the accessory rail 50 using any suitable technique or techniques at 206. For example, in one or more embodiments, the accessory 70 can be connected to the accessory mount 72, which is then connected to the groove 62 of the accessory rail 50. At 208, the accessory 70 can be removed from the accessory rail 50 using any suitable technique or techniques. In one or more embodiments, the accessory 70 can remain connected to the accessory rail 50 as the rail is removed from the plate 32 at 210. The accessory rail 50 can be removed from the plate 32 using any suitable technique or techniques. In one or more embodiments, one or more threaded screws or bolts can be removed from the through-holes 58, 60 and the bosses 38, 40, and the rail 50 can be disconnected from the plate 32 by moving the rail in a direction orthogonal to the outer surface 14 of the ballistic layer 12 of the helmet 10.

In general, the accessory mounting systems described herein are designed such that an accessory mounted to the system is retained in a desired position and orientation while the helmet that includes the accessory mounting system is in use. In one or more embodiments, the accessory mounting system can be designed such that one or more elements of the system disengage when under a predetermined force such that the helmet does not become entangled or snagged on one or more elements surrounding the user, e.g., tree branches, rubble, cables, cords, wires, door and window frames, etc. In one or more embodiments, the accessory mounting system can be designed such that the accessory disengages from the mounting system when encountering such environmental elements.

In one or more embodiments, the accessory 70 can be retained on the accessory mount 72 with an accessory retention force. The accessory retention force can include any suitable value of retention force such that the accessory remains connected to the mount. In one or more embodiments, the accessory retention force does not exceed a maximum accessory retention force. As used herein, the term “maximum accessory retention force” means a force that retains the accessory 70 on the accessory mount 72 such that the accessory remains connected to the mount when encountering typical forces that may engage the accessory when the wearer is in the field. Further, in one or more embodiments, the accessory mount 72 can be retained on the accessory rail 50 with a mount retention force. The mount retention force can include any suitable value. In one or more embodiments, the accessory rail 50 can be retained on the plate 32 with a rail retention force. The rail retention force can also include any suitable value. In one or more embodiments, the accessory retention force is less than the mount retention force such that the accessory can become disengaged from the mount prior to the mount becoming disengaged from the rail. Further, in one or more embodiments, the mount retention force can be less than the rail retention force such that the mount can become disengaged from the rail prior to the rail disengaging from the plate 32.

In one or more embodiments, the plate 32 can be retained on the helmet 10 with a plate retention force that can be any suitable value. In one or more embodiments, the rail retention force can be less than the plate retention force such that the rail can become disengaged from the plate prior to the plate becoming disengaged from the helmet, thereby preventing the helmet from becoming permanently damaged and requiring replacement.

One or more embodiments of accessory mounting systems described herein can be provided in a kit such that a manufacturer can connect the system to a helmet in the field. For example, FIG. 9 is a schematic plan view of one embodiment of an accessory mounting system kit 300. Although described regarding the helmet 10 and accessory mounting system 30 of FIGS. 1-3, the kit 300 can be utilized with any suitable helmet and accessory mounting system. The kit 300 includes a template 302 that is adapted to be disposed on the outer surface 14 of the ballistic layer 12 of the helmet 10. The template can include one or more openings or patterns that direct the user to portions of the outer surface 14 of the ballistic layer 12 where one or more attachment elements utilized to connect the rail 32 to the helmet 10 can be positioned. In one or more embodiments, the one or more openings of the template can be adapted to expose a substantially continuous portion of the ballistic layer of the helmet.

The kit 300 can also include an adhesive 304. Any suitable adhesive or combination of adhesives can be included that are adapted to connect the plate 32 to the substantially continuous portion of the ballistic layer 12, e.g., primers and combinations of adhesives and primers. A surface cleaning component 306 adapted to clean the substantially continuous portion of the ballistic layer 12 can also be included in the kit 300. Any suitable surface cleaning component or components can be utilized, e.g., solvents such as isopropyl alcohol, water, methyl ethyl ketones (MEK), etc.

The kit 300 can also include an abrasive element 308 that is adapted to abrade the substantially continuous portion of the ballistic layer 12 of the helmet 10 to assist in connecting the rail 32 to the outer surface 12 of the ballistic layer. Any suitable abrasive element or elements can be included, e.g., sandpaper, sanding blocks, scouring pads, etc. The kit 300 also includes the plate 32 and the accessory mounting rail 50.

Further, in one or more embodiments, the kit 300 includes a fixturing plate 310 that is adapted to be connected to the helmet and apply pressure to the plate 32 as the plate is connected to the substantially continuous portion of the ballistic layer 12 of the helmet 10. The fixturing plate 310 can include any suitable fixturing plate or clamping device that can maintain the position of the plate 32 as the plate, e.g., is adhered to the ballistic layer 12. In one or more embodiments, the fixturing plate 310 can include one or more through-holes or openings through which one or more bolts can be inserted to connect the fixturing plate to the helmet 10. For example, in one or more embodiments, the helmet 10 can include one or more through-holes that are utilized to connect the suspension system. These through-holes can be utilized to connect the fixturing plate 310 to the helmet prior to installation of the suspension system to the helmet 10.

Any suitable technique or techniques can be utilized to dispose the accessory mounting systems 30, 31 to the helmet 10. For example, FIG. 11 is a flow chart of one method 400 of disposing the helmet mounting system 30 on the helmet 10. Although described regarding the helmet 10 and helmet mounting system 30 of FIGS. 1-3, the method 400 can be utilized with any helmet and helmet mounting system. At 402, a template (e.g., template 302 of kit 300) can be disposed on the outer surface 14 of the ballistic layer 12 of the helmet 10. The template can include any suitable template that can be utilized to position the rail 32 and the desired location or locations on the helmet 10. In one or more embodiments, the template includes one or more openings that can be positioned in the desired location on the helmet 10 where the rail 32 will be positioned. The opening or openings can expose a portion of the ballistic layer 14 where the rail 32 will be disposed. In one or more embodiments, the exposed portion is a substantially continuous portion of the ballistic layer. After disposing the template on the outer surface 14 of the ballistic layer 12, the exposed outer surface can optionally be prepared using any suitable technique or techniques, e.g., roughening the surface using an abrasive element (abrasive element 308), cleaning the surface with a surface cleaning component (surface cleaning component 306), etc. At 404, an adhesive (e.g., adhesive 304 of kit 300) can be disposed on the exposed portion of the ballistic layer 14 where the rail 32 will be connected. The adhesive can be disposed through the opening of the template using any suitable technique or techniques. At 406, the plate 32 can be connected to the exposed portion of the ballistic layer 14 using any suitable technique or techniques. In one or more embodiments, the plate 32 is connected to the exposed portion of the ballistic layer 12 utilizing the adhesive. At 408, pressure can be applied to the plate 32 using any suitable technique or techniques. For example, the fixturing plate 310 of the kit 300 of FIG. 9 can be utilized to apply pressure to the plate 32. In embodiments where an adhesive is utilized to connect the plate 32 to the helmet 10, the adhesive can be cured using any suitable technique or techniques at 410 such that the plate is permanently attached to the ballistic layer 12 of the helmet. Further, at 412, the accessory rail 50 can be connected to the plate 32 using any suitable technique or techniques.

Various embodiments of the present invention include the following:

Embodiment 1

An accessory mounting system comprising: a plate adapted to be permanently connected to a substantially continuous portion of a ballistic layer of a helmet, the ballistic layer having an outer surface, and wherein the plate comprises an inner surface and an outer surface, wherein the inner surface of the plate is adapted to be disposed in contact with the outer surface of the ballistic layer; and an accessory rail adapted to be removably connected to the plate, wherein the accessory rail comprises an inner surface and an outer surface, and wherein the inner surface of the accessory rail is adapted to be disposed in contact with the plate.

Embodiment 2

The system of Embodiment 1, wherein the plate is adapted to be permanently connected to the substantially continuous portion of the ballistic layer of the helmet by an attachment element that does not penetrate through a thickness of the helmet.

Embodiment 3

The system of Embodiment 2, wherein the attachment element comprises a permanent adhesive.

Embodiment 4

The system of any one of Embodiments 2-3, wherein the attachment element comprises a threaded screw having a length that is less than a thickness of the ballistic layer of the helmet.

Embodiment 5

The system of any one of Embodiments 2-4, wherein the attachment element comprises a barb having a length that is less than a thickness of the ballistic layer of the helmet.

Embodiment 6

The system of any one of Embodiments 1-5, further comprising an accessory mount adapted to engage a groove of the accessory rail and connect an accessory to the accessory rail.

Embodiment 7

The system of Embodiment 6, wherein the accessory is releasably connected to the accessory mount.

Embodiment 8

The system of any one of Embodiments 1-7, wherein the plate is rigid.

Embodiment 9

The system of any one of Embodiments 1-8, wherein the accessory rail is rigid.

Embodiment 10

The system of any one of Embodiments 1-9, wherein the inner surface of the plate comprises a shape that is adapted to conform to a shape outer surface of the substantially continuous portion of the ballistic layer of the helmet.

Embodiment 11

The system of any one of Embodiments 1-10, wherein the accessory rail comprises a recess disposed in the inner surface of the accessory rail that is adapted to receive the plate.

Embodiment 12

The system of any one of Embodiments 1-11, wherein the accessory rail is connected to the plate with a threaded screw inserted through a screw hole disposed through the accessory rail and a boss disposed in the plate.

Embodiment 13

The system of Embodiment 12, wherein the boss disposed in the plate has a depth that is less than a thickness of the plate such that the boss does not extend to the inner surface of the plate.

Embodiment 14

The system of any one of Embodiments 1-13, wherein the plate comprises a slot adapted to slidably receive a tab disposed on the inner surface of the accessory rail.

Embodiment 15

The system of any one of Embodiments 1-14, wherein the substantially continuous portion of the ballistic layer is disposed on a side portion of the helmet.

Embodiment 16

The system of any one of Embodiments 1-14, wherein the substantially continuous portion of the ballistic layer is disposed on a front portion of the helmet.

Embodiment 17

A helmet comprising: a ballistic layer comprising an inner surface and an outer surface; and an accessory mounting system comprising a plate and an accessory rail removably connected to the plate, wherein the plate comprises an inner surface and an outer surface, wherein the inner surface of the plate is permanently connected to a substantially continuous portion of the ballistic layer by an attachment element, wherein the accessory rail comprises an inner surface and an outer surface, and further wherein the inner surface of the accessory rail is in contact with the plate when the accessory rail is connected to the plate.

Embodiment 18

The helmet of Embodiment 17, wherein the attachment element does not penetrate through the inner surface of the ballistic layer.

Embodiment 19

The helmet of Embodiment 17, wherein the attachment element comprises an adhesive.

Embodiment 20

The helmet of Embodiment 17, wherein the attachment element comprises a threaded screw.

Embodiment 21

The helmet of any one of Embodiments 17-19, wherein the substantially continuous portion of the ballistic layer is disposed on a side portion of the helmet.

Embodiment 22

The helmet of any one of Embodiments 17-19, wherein the substantially continuous portion of the ballistic layer is disposed on a front portion of the helmet.

Embodiment 23

The helmet of any one of Embodiments 17-22, further comprising an accessory mount releasably connected to a groove of the accessory rail, and an accessory releasably connected to the accessory mount.

Embodiment 24

The helmet of Embodiment 23, wherein the accessory is retained on the accessory mount with an accessory retention force, wherein the accessory retention force does not exceed a maximum accessory retention force, the accessory mount is retained on the accessory rail with a mount retention force, and the accessory rail is retained on the plate with a rail retention force, wherein the accessory retention force is less than the mount retention force, and further wherein the mount retention force is less than the rail retention force.

Embodiment 25

The helmet of Embodiment 24, wherein the plate is retained on the helmet with a plate retention force, wherein the rail retention force is less than the plate retention force.

Embodiment 26

A method comprising: connecting a plate to an outer surface of a ballistic layer of a helmet; connecting an accessory rail to the plate; connecting an accessory to the accessory rail; removing the accessory from the accessory rail; and removing the accessory rail from the plate by moving the accessory rail in a direction orthogonal to an outer surface of a ballistic layer of the helmet.

Embodiment 27

A method comprising: disposing a template on an outer surface of a ballistic layer of a helmet, wherein the template comprises an opening that exposes a portion of the ballistic layer; disposing an adhesive on the exposed portion of the ballistic layer through the opening of the template; connecting a plate to the exposed portion of the ballistic layer utilizing the adhesive; applying pressure to the plate; and curing the adhesive such that the plate is permanently attached to the ballistic layer of the helmet.

Embodiment 28

An accessory mounting system kit comprising: a template adapted to be disposed on an outer surface of a ballistic layer of a helmet, wherein the template comprises an opening that is adapted to expose a substantially continuous portion of the ballistic layer of the helmet; an adhesive; a surface cleaning component adapted to clean the substantially continuous portion of the ballistic layer of the helmet; an abrasive element adapted to abrade the substantially continuous portion of the ballistic layer of the helmet; a plate adapted to be permanently connected to the substantially continuous portion of the ballistic layer of the helmet; an accessory rail adapted to be removably connected to the plate; and a fixturing plate adapted to be connected to the helmet and apply pressure to the plate as the plate is connected to the substantially continuous portion of the ballistic layer of the helmet.

All references and publications cited herein are expressly incorporated herein by reference in their entirety into this disclosure, except to the extent they may directly contradict this disclosure. Illustrative embodiments of this disclosure are discussed and reference has been made to possible variations within the scope of this disclosure. These and other variations and modifications in the disclosure will be apparent to those skilled in the art without departing from the scope of the disclosure, and it should be understood that this disclosure is not limited to the illustrative embodiments set forth herein. Accordingly, the disclosure is to be limited only by the claims provided below. 

1. An accessory mounting system comprising: a rigid plate having an elastic modulus (Young's Modulus) of at least 0.1 GPa and no greater than 1000 GPa as measured using ASTM E111-04(2010) and adapted to be permanently connected to a substantially continuous portion of a ballistic layer of a helmet by an attachment element, the ballistic layer having an outer surface, and wherein the plate comprises an inner surface and an outer surface, wherein the inner surface of the plate is adapted to be disposed in contact with the outer surface of the ballistic layer; and an accessory rail adapted to be removably connected to the plate, wherein the accessory rail comprises an inner surface and an outer surface, and wherein the inner surface of the accessory rail is adapted to be disposed in contact with the plate, wherein the attachment element does not penetrate through a thickness of the helmet.
 2. (canceled)
 3. The system of claim 1, wherein the attachment element comprises a permanent adhesive.
 4. The system of claim 1, wherein the attachment element comprises a threaded screw having a length that is less than a thickness of the ballistic layer of the helmet.
 5. The system of claim 1, wherein the attachment element comprises a barb having a length that is less than a thickness of the ballistic layer of the helmet.
 6. The system of claim 1, further comprising an accessory mount adapted to engage a groove of the accessory rail and connect an accessory to the accessory rail.
 7. The system of claim 1, wherein the accessory rail comprises a recess disposed in the inner surface of the accessory rail that is adapted to receive the plate.
 8. The system of claim 1, wherein the accessory rail is connected to the plate with a threaded screw inserted through a screw hole disposed through the accessory rail and a boss disposed in the plate, wherein the boss disposed in the plate has a depth that is less than a thickness of the plate such that the boss does not extend to the inner surface of the plate.
 9. The system of claim 1, wherein the plate comprises a slot adapted to slidably receive a tab disposed on the inner surface of the accessory rail.
 10. A helmet comprising: a ballistic layer comprising an inner surface and an outer surface; and an accessory mounting system comprising a rigid plate having an elastic modulus (Young's Modulus) of at least 0.1 GPa and no greater than 1000 GPa as measured using ASTM E111-04(2010) and an accessory rail removably connected to the plate, wherein the plate comprises an inner surface and an outer surface, wherein the inner surface of the plate is permanently connected to a substantially continuous portion of the ballistic layer by an attachment element, wherein the accessory rail comprises an inner surface and an outer surface, and further wherein the inner surface of the accessory rail is in contact with the plate when the accessory rail is connected to the plate, wherein the attachment element does not penetrate through the inner surface of the ballistic layer.
 11. (canceled)
 12. The helmet of claim 10, wherein the attachment element comprises an adhesive or a threaded screw.
 13. The helmet of claim 10, further comprising an accessory mount releasably connected to a groove of the accessory rail, and an accessory releasably connected to the accessory mount.
 14. The helmet of claim 13, wherein the accessory is retained on the accessory mount with an accessory retention force, wherein the accessory retention force does not exceed a maximum accessory retention force, the accessory mount is retained on the accessory rail with a mount retention force, and the accessory rail is retained on the plate with a rail retention force, wherein the accessory retention force is less than the mount retention force, and further wherein the mount retention force is less than the rail retention force.
 15. The helmet of claim 14, wherein the plate is retained on the helmet with a plate retention force, wherein the rail retention force is less than the plate retention force.
 16. A method comprising: permanently connecting a rigid plate having an elastic modulus (Young's Modulus) of at least 0.1 GPa and no greater than 1000 GPa as measured using ASTM E111-04(2010) to an outer surface of a ballistic layer of a helmet by an attachment element that does not penetrate through a thickness of the helmet; connecting an accessory rail to the plate; connecting an accessory to the accessory rail; removing the accessory from the accessory rail; and removing the accessory rail from the plate by moving the accessory rail in a direction orthogonal to an outer surface of a ballistic layer of the helmet.
 17. A method comprising: disposing a template on an outer surface of a ballistic layer of a helmet, wherein the template comprises an opening that exposes a portion of the ballistic layer; disposing an adhesive on the exposed portion of the ballistic layer through the opening of the template; connecting a plate to the exposed portion of the ballistic layer utilizing the adhesive; applying pressure to the plate; and curing the adhesive such that the plate is permanently attached to the ballistic layer of the helmet.
 18. An accessory mounting system kit comprising: a template adapted to be disposed on an outer surface of a ballistic layer of a helmet, wherein the template comprises an opening that is adapted to expose a substantially continuous portion of the ballistic layer of the helmet; an adhesive; a surface cleaning component adapted to clean the substantially continuous portion of the ballistic layer of the helmet; an abrasive element adapted to abrade the substantially continuous portion of the ballistic layer of the helmet; a plate adapted to be permanently connected to the substantially continuous portion of the ballistic layer of the helmet; an accessory rail adapted to be removably connected to the plate; and a fixturing plate adapted to be connected to the helmet and apply pressure to the plate as the plate is connected to the substantially continuous portion of the ballistic layer of the helmet. 